STANDARD BULK TRUCK SYSTEMSTANDARD BULK TRUCK SYSTEM
INSTALLATION PROCEDURESINSTALLATION PROCEDURES
LectroCount³
Table Of Contents
SECTION page
1. System Overview 3
2. Installation Overview 4
3. Parts Requirements 4
3.1 Liquid Controls Supplied Components 4
3.2 Liquid Controls Supplied Options 4
3.3 Installer Supplied Parts 4
4. Electrical Check 5
5. Truck Cab Computer Installation 6
5.1 General Requirements 6
5.2 Locating Components 6
5.3 Electrical Power Connections 7
5.3.1 Overview 7
5.3.2 Run Battery Cable 7
5.3.3 Installation of Accessory Cable 8
5.4 Truck Seat Grounding 9
5.4.1 Static Electricity and Grounding 9
5.4.2 Installation of Ground Strap Kit 10
6. Supervisory Console Grounding 12
6.1 Grounding Strap Installation 13
7. Lap Pad Connection 14
8. Printer Mounting 14
8.1 Printer Connection & Printer Dimensional Drawing 14 & 15
9. Removal of Mechanical Registration Equipment 15
10. Installation of Electronic Temperature Volume Compensator 15
10.1 Installation of Strainer Cover Mounted Thermowells 16 & 17
10.2 Installation of Pipe Mounted Thermowells 18
10.2.1 For Canadian Installations 18
11. Mounting the Remote Supervisory Control Box (RSCB) 19
11.1 Liquid Controls Meters/RSCB with Internal Pulsers 19
11.2 LC Meter with External Pulse Output Device 20
11.3 Neptune Non-Compensated Meter Retrofit Kit 21
11.4 Neptune Temperature Compensated Meter Retrofit Kit 22
11.5 RSCB Mounting Bolt Pattern 23
12. Wiring the RSCB 24
12.1 Wiring of the Valve Solenoids to the RSCB 25
12.1.1 "Diddle" Valve Wiring 26
12.1.2 Liquid Controls Dual Stage Wiring 26
12.1.3 Single Stage Valve and Three Way Solenoid Wiring 26
12.2 Wiring of the RTD Temperature Probe to the RSCB 26
12.3 POD Wiring (Pulse Output Device) 26
12.4 Internal Pulser Wiring 27
12.5 Truck Cab Cable Routing 27
12.6 Connection of the Meter Signal Cable 28
12.6.1 Single Meter Systems 28
12.6.2 Dual Meter Systems 28
13. System Start-Up 28
14. Software Part Numbering System 29
15. Troubleshooting 29 - 37
16. Wiring Diagrams 38
16.1 Mounting Arrangements for Components w/ Brackets 43
1. System Overview
The LectroCount3 On-Board Truck
Computer system works in conjunction
with many models of Positive
Displacement Flow Meters. It
accurately measures fuel deliveries,
prints priced receipts, and streamlines
driver record keeping. It can be
equipped with accessories that allow for
temperature volume compensation,
deliveries to be made (net volume), and
delivery information to be exchanged
between the truck computer and an
office computer.
The basic system consists of:
1. Remote Supervisory Control
Box/Remote Electronic Counter
Assembly (RSCB/REC) that is
mounted in place of mechanical
registration equipment on the meter.
2. Supervisory Control Module and
Printer that are mounted in the truck
cab.
3. Lap Pad operator interface.
For trucks equipped with two meters, a
dual meter configuration is available that
allows two RSCB/RECs to be connected
to a single truck computer.
This manual describes the installation of
these components and their
accessories. Read this entire
installation manual before beginning
the installation to make sure that you
understand the total scope of the
project. Specific installation
requirements will vary with the model of
truck. Meter type, configuration of
existing metering equipment, selected
options, and the type of fluid being
metered, all influence installation. Make
sure that the RSCB/REC, Electronic
Temperature Volume Compensation kit
(ETVC), pulser, and valves can be
installed in such a manner so as to not
interfere with routine service of the
meter, the strainer, and the meter
compartment door.
The conduit and wiring for the above
components need to be routed with
similar concerns in mind. If a dual meter
system is being installed, the
RSCB/REC, ETVC, pulser, and valve
work must be duplicated for the second
meter.
NOTE: Power, input and output (I/O) wiring must be in accordance with
Class I, Division 2, wiring methods in Article 501-4(b) of the National
Electrical Code, NFPA 70 and in accordance with the authority having
jurisdiction.
WARNING: Explosion Hazard - Substitution of Components May
WARNING: Explosion Hazard - When in Hazardous Locations, Turn
WARNING: Explosion Hazard - Do NOT Disconnect Equipment
Impair Suitability for Class I, Division 2.
Off Power Before Replacing or Wiring Modules;
Unless Power Has Been Switched Off or the Area is
Known to be Non-hazardous.
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2. Installation Overview
q Ensure that the truck electrical
system meets specifications and
can provide at least 5 Amps for
the LectroCount3 with all truck
accessories operating.
q Electrically ground the truck
seats.
q Mount supervisory control
module and printer in cab.
q Install battery/accessory cables.
q Install odometer kit (optional).
q Remove any existing mechanical
q Remove any existing manual
preset valve.
q Install an electronically controlled
security valve or solenoid kit.
q Mount RSCB / REC
q Install pulser assembly (optional)
q Install Electronic Temperature
Volume Compensation Kit
(optional).
q Route Meter Signal Cable to
truck cab.
registration equipment.
3. Parts Requirements
3.1 LIQUID CONTROLS SUPPLIED COMPONENTS
q RSCB / REC
q Meter Signal Cable (pre-wired to RSCB)
q Battery/Accessory Cable
q Supervisory Control Module
q Lap Pad (driver key pad)
q Ticket Printer with cables
3.2 LIQUID CONTROLS SUPPLIED OPTIONS
q ETVC Kit
q Pulse Output Device (pulser)
q Odometer Pulser
q Dual Meter Switch Box
q RAM Interface Module
q Two Stage Valve or 3-Way Solenoid
3.3 INSTALLER SUPPLIED PARTS
q Protective Sheathing/Conduit for cables
q All Fittings
q Hardware for Truck Computer Mounting Brackets
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4. Electrical Check
Before beginning to install the LectroCount3, it is essential that you complete the
following checklist. If the vehicle electrical system cannot meet the following
requirements, corrective action must be taken before installing the LectroCount3. This
checklist is also included with the system. That copy should be filled out and filed with
the distributor or truck builder. NOTE: Contact the factory if the truck has a positive
ground.
The truck system must meet the following requirements:
q Battery terminals and cables must be in good condition with clean, corrosion free
connections.
q Battery must be charged in accordance with manufacturer’s specifications.
q The alternator must be large enough to meet the total demands of the truck,
including the LectroCount3. LectroCount3 requires 5A minimum for proper
operation. A typical alternator size is 90 amperes.
q If the truck has a history of electrical problems, make sure that these problems
have been corrected before installing the LectroCount3.
q Inspect all truck electrical/electronic equipment for proper installation.
q Determine if the truck is positive or negative ground. (If the system is positive
ground, contact the factory).
q Be sure that the radio antennas were installed in accordance with the
manufacturer’s specifications to prevent RF interference.
To ensure that these requirements are met, check the voltage across the battery
terminals under the following conditions:
LectroCount
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Vehicle Inspection Check List
With the truck running at low idle, and all accessories off, the voltage should be between
12.6 and 18 VDC.
With all the accessories (lights, heater, radio, and radio mike) on, the voltage must be
between 12.6 and 18 VDC. If the voltage drops significantly when the accessories
are turned on, it may indicate that the alternator will not be able to support the
LectroCount3.
Extend the delivery hose to its full length, engage the hose reel and measure the voltage
as the hose is reeled in. It shouldn’t drop below 10VDC.
With the truck running at high idle, and all accessories off, check the voltage. Again it
should be between 12.6 and 18 VDC.
Repeat the hose reel test with the truck at high idle. Make sure that the voltage does not
drop below 10 VDC.
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5. Truck Cab Computer Installation
5.1 GENERAL REQUIREMENTS
A minimal truck cab computer system
includes:
1. A supervisory control module (SCM)
that is mounted between two right
angle brackets
2. A dot matrix ticket printer
3. A Lap Pad (key pad/display).
Systems equipped with the RAM card
option will have a RAM interface module
mounted atop the supervisory control
module. Dual meter systems will have a
Dual Meter Switch mounted below the
SCM. (See Figure to the right)
The truck computers are shipped with
the components and brackets
assembled. The installer has to bolt the
brackets to the cab floor, ground the
SCM to the truck electrical system, and
route the power and signal cables to the
appropriate connectors on the SCM and
Dual Meter Switch.
Component Configuration
Single Meter/Non-RAM Configuration
Truck Cab
The printer also needs to be mounted in
the truck cab, usually on top of the SCM
“stack”. The Lap Pad is secured in a
holder on the side of one of the
brackets.
5.2 LOCATING COMPONENTS
The SCM bracket should be mounted in
a location where:
q Both the front and back can be
accessed to connect cables
q The Lap Pad and printer will be
accessible to the driver.
q The Supervisory Control Module
fuses can be replaced.
q There is enough room to insert and
remove a RAM card from the RAM
interface module. (RAM systems
only)
Single Meter / RAM Configuration
Dual Meter / RAM System
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5.3 ELECTRICAL POWER CONNECTIONS
5.3.1 Overview
The LectroCount3 is designed to run only
when the ignition switch is in the “on” or
“accessory” position. This prevents the
LectroCount3 from being damaged by
the voltage spikes or electrical noise
that occur when the starter is engaged,
or from draining the truck battery power
when the truck isn’t running.
Voltage from the battery is switched by
a relay that is controlled by the truck’s
accessory circuit. It is vital that the
battery and accessory cables be
properly connected and fused, and that
the SCM is properly grounded.
5.3.2 Run Battery Cable
(Part Number 81232)
The battery cable is supplied with
heavy-duty ring terminals that must be
installed directly to the battery posts.
Make sure that the truck’s electrical
system has been properly checked.
Clean the battery terminals for a
good electrical connection.
q Remove the ATO 7.5 amp fuse from
the battery cable’s black splashproof fuse holder so that the wire is
not live while the cable is routed and
terminated.
q Attach the black cable to the
negative (-) terminal of the battery.
q Connect the orange cable terminal
to the positive (+) terminal of the
battery.
q On truck systems with several
batteries connected in parallel, the
last battery in the system usually has
the least number of connections and
will be the best location to attach the
battery cable.
q Route the cable to the supervisory
control module in the truck cab.
q Seal any holes that you may have
made in the cab wall.
(continued next page)
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q Make sure that you route the cable
in such a manner so as not to
interfere with the operation or
maintenance of the truck.
q The wires will be connected to a
three pin terminal block on the back
of the SCM.
q The block can be removed from the
SCM to ease the process.
q Use a 1/8” screwdriver to back off
the terminal block screws.
q Strip 7/32” of insulation from the
wires.
q Connect the white wire to Pin 2 on
the block and connect the black wire
to Pin 3.
q Make sure that the screws are re-
tightened and that no loose strands
of wire are exposed.
5.3.3 Install Accessory Cable
(Part Number 80747)
The accessory cable consists of a RED and a BLACK conductor in a shielded cable.
The conductors are both connected to the same ring terminal on one end. They are not
terminated on the other end.
The accessory cable must be wired to the truck’s accessory circuit. The power to this
circuit should be:
q OFF when the ignition is off or the engine is cranking,
q ON when the truck is running or the ignition switch is in the “accessory”
position:
Key Switch OFF 0VDC
Key Switch ON 12 VDC (battery voltage)
Key Switch ACCESSORY 12 VDC (battery voltage)
Key Switch or starter button CRANKING 0 VDC
q Check the voltage using an accurate multi-meter.
q Be sure to use a good ground to avoid false readings.
q The voltage should drop momentarily to 0 as the engine is cranked.
If the ignition switch is accessible:
q Connect the ring terminal on the
accessory cable to the accessory
stud on the switch.
q It is usually best to install the ring
terminal over the stud and the nut
that hold the existing accessory
wires in place.
q An additional nut should then be
used to hold the LC accessory cable
on the stud.
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If the ignition switch is not
accessible:
q Install a voltage tap on the
accessory fuse.
q Remove the ring terminal from the
accessory cable.
q Connect both the red and black
conductors in the cable to the fuse
tap.
q Trim back the drain wire and foil
shield at the outer insulation on the
cable.
q Use electrical tape or heat
shrinkable tubing to insulate the
edge of the shield.
q Route the cable to the rear of the
supervisory control module.
5.4 TRUCK SEAT GROUNDING
5.4.1 Static Electricity and Grounding
q Trim the cable to the appropriate
length and strip back the outer
insulation, foil shield, and drain wire.
q Use electrical tape or heat
shrinkable tubing to insulate the
edge of the shield.
q Remove 7/32” of insulation from
both the red and black conductors,
twist the wires together, and insert
them in Pin 1 of the three pin
terminal block.
q Tighten the terminal block screw
using 1/8” flat blade screwdriver.
q Plug the terminal black back into the
SCM.
Static electricity can build up on drivers
and truck seats, especially during cold,
dry weather. Adjustable, shockabsorbing seats add to the problem
because they isolate the seat cushion
from an electrical ground. If the static is
it can cause the truck computer to reset
and/or cause a number of other hard to
trace faults. The discharge can occur
when the driver touches the
LectroCount3 or a part of the truck that
provides a good ground path.
discharged on or near the LectroCount3,
WARNING
To prevent the occurrence of electrostatic discharge (ESD), it is
mandatory that the truck seat(s) be properly grounded. This allows
the static electricity to “bleed off’ the driver and seat before it can
build up to the point where a discharge can interfere with the
operation of the LectroCount3 (or cause an explosion in hazardous
environments!)
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5.4.2 Installation of Ground Strap Kit
q Locate a good ground point near the back of the seat frame. The bottom of the seat
base bracket is usually a good spot.
q Drill a 9/32” hole in the seat frame near the back of the base.
q Attach one end of the ground strap to the bracket using the lock washer, flat washer
and nut provided. The lock washer should penetrate any paint on the bracket to
ensure a good electrical connection.
q Attach the other end of the strap to a metal part of the seat frame at a point where it
contacts the seat cushion. Make sure that there are no intervening pivot points,
guides, adjustment mechanisms, etc., which could interfere with the ground path
between the seat cushion and the ground strap.
q If the seat cushion has a wooden base, use a wood screw and washer to attach the
strap lug to the bottom of the seat at a point where the seat fabric is attached to the
wood. There must be good contact between the seat fabric and ground strap lug.
q Make sure that the strap is positioned so that it doesn’t interfere with the movement
of the seat or is exposed to physical damage.
Checking for a good ground
The resistance should be checked. Use a multi-meter to test the resistance between a
bare spot on the seat frame and PIN 3 on the SCM power connector.
(The ground terminal should be connected directly to the negative terminal of the battery
on a negative ground system)
The test should be done with all accessories, including the dome light, turned OFF. This
will prevent other currents from distorting the measurement.
If the resistance is less than 3 ohms:
The system is grounded sufficiently and no further action is necessary.
If the resistance is greater than 3 ohms:
Locate a better ground on the base of the seat or at some other point in the cab.
“Fan fold” the excess ground strap and tie it with a wire tie to the back of the seat frame.
Make sure that you have left enough slack in the strap to accommodate the seat’s full
range of adjustment.
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A. Air Cushion Type Seat-Adjustable for Height (Bostrom 914 Series Seat or
Equivalent)
B. Air Cushion Type Seat-Adjustable for Height (This includes Dura-Form
Seats or equivalent)
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C. Bench Style Seats-Adjustable for Distance to Steering Wheel (Includes
Manufacturers Standard Production Seats
6. Supervisory Control Module Grounding
The Supervisory Control Module (SCM) case must be grounded to a good chassis
ground on the truck to ensure proper operation. Usually, a good ground path is
established from the SCM case through the mounting brackets and bolts to the chassis.
The ground effectiveness can be reduced over time due to corrosion, dirt, etc., leading to
electrostatic discharge problems.
The ground path should be checked, whenever the LectroCount³ is serviced. This
ensures that the SCM’s case remains properly grounded.
Checking for a good ground:
Resistance should be checked using a multi-meter. Testing should be done with all
accessories, including the dome light, turned OFF to prevent other currents from
distorting the measurement.
Measure the resistance between one of the silver hex head screws on the LectroCount³
mounting bracket and the ground terminal (Pin 3) on the power plug of the SCM.
(The ground terminal should be connected directly to the negative terminal of the battery
on a negative ground system.)
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If the resistance is less than 3 ohms:
The system is grounded sufficiently and no further action is necessary.
If the resistance is greater than 3 ohms:
A grounding strap needs to be attached between the mounting bracket and a
good ground in the cab.
6.1 GROUNDING STRAP INSTALLATION
Mobile Installations
One end of the strap should be attached to the SCM mounting bracket per the following
picture:
Use a star washer between the lug and the bracket. Make sure that the washer
penetrated the paint on the bracket. Attach the other end of the strap to a convenient
ground point in the cab.
The bolt used to ground the seat ground strap on the seat base is usually a good
location. Measure the resistance between the silver hex head screw and (Pin3) again to
make sure that the system is grounded sufficiently.
If the resistance is still greater than 3 ohms:
• Make sure that the proper metal to metal contact is being made on both ends
of the grounding strap. Clean any paint or oxidation that may have
accumulated on the grounding point. Recheck the resistance again.
• Attach the ground strap to another ground point in the cab and repeat the
process.
Fixed Installations
If the LectroCount3 is being installed in a fixed installation, a ground wire should be
connected between one of the silver hex head screws on the SCM chassis and earth
ground on the power supply.
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7. Lap Pad Connection
The “D” connector on the end of the Lap Pad’s coiled
cable should be plugged into the socket labeled “Lap
Pad” on the front of the supervisory console. Tighten
the two captive screws on the connector to hold it in
place.
8. Printer Mounting
8.1 PRINTER CONNECTION
The printer is connected to the
supervisory console via data cable and
a power cable.
The data cable is terminated with a 25
Pin D-connector on the printer end.
The printer is usually mounted on top of the top
module of the SCM bracket assembly. It can
also be mounted on the dash, the passenger
seat, or any other location in the cab that is:
• Level
• Not subject to physical abuse
• Easy for the driver to reach
• Within reach of the printer’s data and
power cables
Industrial strength Velcro (supplied with the
printer) is used to hold the printer in place.
Always place the same type of Velcro (hook or
loop) on the printer to enable easy replacement.
This plugs into the socket labeled “RS232” on the back of the printer, and into
the socket labeled “Printer Signal” on
the supervisory console.
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